Application Note - AN9003 Section 2

2 An Introduction to Intrinsic Safety

Hazardous area Non-hazardous area
Zone 0 Zone 1 Safe area

Circuit A Circuit B Circuit C

Temperature Intrinsically Uncertified

Transmitter Safe Apparatus
Interface
RTD
Cable x A
1 1 B Cable y
2 2 4+ 5 1
3 3 5– 4 2
3
4

Figure 2.1 - Typical IS system

2.1 Definition of Intrinsic Safety 2.3 Levels of protection

The definition of intrinsic safety used in the relevant IEC Intrinsic safety utilises three levels of protection, 'ia', 'ib' and 'ic'
apparatus standard IEC 60079-11 is a 'type of protection based which attempt to balance the probability of an explosive
on the restriction of electrical energy within apparatus and of atmosphere being present against the probability of an ignition
interconnecting wiring exposed to the potentially explosive capable situation occurring.
atmosphere to a level below that which can cause ignition by 'ia'
either sparking or heating effects'. This is a concise statement of
This offers the highest level of protection and is generally
intent to introduce a multi-faceted subject.
considered as being adequately safe for use in the most
hazardous locations (Zone 0) because the possibility of two
2.2 Typical intrinsically safe system
'faults' (see below) and a factor of safety of 1.5 is considered in
Figure 2.1 illustrates a typical intrinsically safe (IS) system the assessment of safety.
where the safe performance of each piece of apparatus is 'ib'
dependent on the integrity of all the equipment in the system. For
'ib' apparatus, which is adequately safe with one fault and a
example, the safety of the Temperature Transmitter (Tx) depends
factor of safety of 1.5 is considered safe for use in less frequently
upon the amount of energy supplied by the IS Interface.
hazardous areas (Zone 1).
In most process control applications, each piece of apparatus in
'ic'
a system is individually certified. A document that confirms the
safety of the whole system is then produced using the 'ic' apparatus which is assessed in 'normal operation' with a unity
information from the individual apparatus certificates, in factor of safety is generally acceptable in infrequently hazardous
accordance with the system standard IEC 60079-25. This system areas (Zone 2). The 'ic' concept is relatively new (2005) and will
document also includes details of cable types and simple replace the 'energy-limited' (nL) of the type 'n' standard IEC
apparatus used in the system. 60079-15 and possibly the 'non-incendive' concept of North
American standards.
It is important to recognise that where pieces of intrinsically safe
apparatus are interconnected, it is the safety of the system that It is usual for a system to be allocated a level of protection as a
must be established. There are however some examples of whole, depending on the level of protection of the apparatus in
apparatus which stand alone, such as mobile radios and portable the system. However it is possible for different parts of a system
gas detectors, where the system approach is not relevant. to have different levels of protection where suitable segregation
exists. This must be made clear in the system documentation.

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2.4 Faults Typical Gas Gas Group Ignition energy
If a fault can adversely affect the safety of the equipment it is Methane IIA 160µJ
called a 'countable' fault.
Ethylene IIB 80µJ
The situation is further complicated because the apparatus
standard permits some specially designed components to be Hydrogen IIC 20µJ
regarded as infallible and some inadequately designed features
Table 2.1: Typical gases, their classification & ignition energies
to be failed in normal operation. Consequently there are faults
that are not considered to happen, faults, which are counted, and The table above shows a representative gas for each group and
faults, which are imposed but not counted. the minimum energy required to ignite it. IIC is clearly the most
sensitive.
One of the major advantages of intrinsic safety is that 'live
maintenance' on equipment is permitted without the necessity of Apparatus can be designed to be acceptably safe in any of these
obtaining 'gas clearance' certificates. A consequence of this is groups. Usually apparatus is designed to be safe in IIC, because
that during the safety analysis the possibility of open circuiting it can then be used in any gas atmosphere. Sometimes a IIB
and short-circuiting any field wiring is regarded as normal classification is used as this permits slightly higher powers to be
operation. available. Only very rarely however is apparatus designed for
the IIA classification because this restricts its use to this group
Fortunately understanding the apparatus standard and faults is
alone.
only necessary for apparatus designers and certifying authorities.
The apparatus certificates remove the necessity to consider Apparatus is usually assessed using the curves and tables
faults, except for field wiring faults, in system design. included in the apparatus standard which lists acceptable levels
of current and voltage. More complex circuits are checked with
2.5 Simple apparatus 'spark test' apparatus; normally the preserve of certifying
authorities.
In general, intrinsically safe apparatus is certified; usually by an
independent body such as an Accredited Certification Body 2.8 Temperature classification
(ACB) under the IEC Ex scheme. Self-certification by the
manufacturer of 'ic' equipment is also quite commonly accepted. The second method of causing an explosion is normally
considered to be ignition by a hot surface. When a gas is heated
The exception to the rule is 'simple apparatus', which is
above its ignition temperature it may spontaneously ignite. The
considered not to appreciably affect the intrinsic safety of the
ignition temperature varies with the gas and is not correlated to
system. This apparatus is exempted from the requirement for
ignition energy. Consequently, when selecting apparatus, both
certification. The simple requirements are clearly specified in the
properties of the explosive gas have to be considered.
apparatus standard.
Apparatus is classified into temperature ('T') classes depending
'Simple apparatus' should always be readily demonstrable to be
on its maximum permitted surface temperature.
adequately safe. The usual examples are switches,
thermocouples, RTDs and junction boxes. T1 T2 T3 T4 T5 T6

2.6 Cables 450°C 300°C 200°C 135°C 100°C 80°C

Because cables have inductance and capacitance, and hence

Table 2.2 The 'T' classes
energy storage capabilities, they can affect system safety.
Consequently the system design imposes restrictions on the The standard enables almost all apparatus, dissipating not more
amount of each of these parameters. A great deal has been than 1.3W, to be allocated a temperature classification of T4
written on this subject but only rarely is there a serious limitation (135°C). Almost all intrinsically safe field mounted apparatus
placed on the available cable. meets the requirements of T4 temperature classification, which
permits its use in all industrial gas atmospheres except in those
As cable faults are taken into account during the system analysis,
comprising carbon disulfide (CS2) and air. These require a T6
the type of cable in individual installations is not closely
classification, which is difficult to achieve at high ambient
specified in the system standard. The choice is therefore
temperatures. There are also toxicity problems associated with
determined by the need for reliable system operation.
carbon disulfide.
Where intrinsically safe systems are combined in a multi-core,
The other temperature that needs to be considered for each piece
then there are special requirements. These determine which
of apparatus is its ambient temperature rating, which does
additional faults have to be considered.
directly affect the safety of the apparatus in several ways.

2.7 Gas classification Apparatus normally mounted in the safe area but which affects
the safety of the intrinsically safe system (such as the
The amount of energy required to ignite a particular gas/air intrinsically safe interface in Figure 2.1) is called 'associated
mixture varies for each gas. apparatus'. Such apparatus does not need to be temperature
Industrial gases capable of being ignited are divided, in the UK, classified but must be used within its specified ambient
into three classes, IIA, IIB and IIC. temperature range.

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2.9 Categories and equipment safety 2.10 Summary
levels
Intrinsic safety offers an acceptable level of safety in all
When the European Directive (ATEX) for apparatus for use in hazardous locations. Arguably it is safer and less prone to
hazardous areas (94/9/EC) was created, it introduced the concept accidental errors than other methods of protection. This
of categories, which was intended to clarify the Zone(s) in which combined with its flexible use of available apparatus and the
apparatus could safely be used. Unfortunately, and for nothing ability to do 'live working' means that it is the natural choice for
more than pedantic reasons, it was decided that a category 0 instrumentation systems in hazardous areas. For example it is the
would not be used and the result was the confusing situation only technique which is readily applicable to Zone 0 locations.
illustrated in Table 2.1, where the category and Zone numbers The introduction of the 'ic' concept completes the picture.
differ. The essential requirements of an intrinsically safe system are:
More recently (2004) the IEC took up the concept of identifying ✦ The system must work.
the level of protection offered by a piece of apparatus and also
✦ The apparatus in the system must be 'certified' or 'simple'.
paid a little more attention to risk analysis as a method of
determining the acceptable use of equipment. The result was the ✦ The compatibility of the apparatus must be established.
creation of equipment protection levels (EPLs), which are ✦ The level of protection of the system established.
similar to ATEX categories but have numbers that align with ✦ The temperature classification and ambient temperature
their normal Zones of use. rating of each piece of apparatus established.
In practice both categories and EPLs align with the levels of ✦ The requirements of the cable established.
protection 'ia', 'ib' and 'ic' as indicated in Table 2.1 and, as far as
intrinsic safety is concerned, they can largely be ignored, as the This extract is part of MTL Application Note AN9003 as
level of protection is already defined as 'ia', 'ib' or 'ic'. They do published on the MTL web site.
however appear on apparatus marking and certificates and
http://www.mtl-inst.com/appnotes/an9003/
consequently need to be explained.

Level of Protection Countable Faults ATEX Category IEC EPL Normal Zone of Use
ia 2 1 0 0
ib 1 2 1 1
ic 0 3 2 2

Table 2.3 Relationships between different methods of assessing safety levels

MTL Instruments, Power Court, Luton, Bedfordshire, England LU1 3JJ August 2006
Tel: +44 (0)1582 723633 Fax: +44 (0)1582 422283 web: www.mtl-inst.com
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